High voltage device

ABSTRACT

A method of forming a device is presented. The method includes providing a substrate having a device region which includes a source region, a gate and a drain region defined thereon. The method also includes implanting the gate. The gate comprises one or more doped portions with different dopant concentrations. A source and a drain are formed in the source region and drain region. The drain is separated from the gate on a second side of the gate and the source is adjacent to a first side of the gate.

CROSS-REFERENCE TO RELATED APPLICATION

This application is a divisional application which claims benefit of copending U.S. patent application Ser. No. 13/352,248, filed Jan. 17, 2012, which is herein incorporated by reference for all purposes.

BACKGROUND

Lateral Double-Diffused (LD) transistors have been widely employed in high voltage applications. One factor which affects the performance of the LD transistors is the gate to drain capacitance (C_(gd)). For example, lower C_(gd) enables faster switching of LDMOS drivers.

Conventional techniques in achieving low C_(gd) can result in increased drain-to-source on-resistance (Rds_(on)), which, in turn, undesirably decreases switching speed.

The disclosure is directed to transistors with fast switching speed.

SUMMARY

A method of forming a device is presented. The method includes providing a substrate having a device region which includes a source region, a gate and a drain region defined thereon. The method also includes implanting the gate. The gate comprises one or more doped portions with different dopant concentrations. A source and a drain are formed in the source region and drain region. The drain is separated from the gate on a second side of the gate and the source is adjacent to a first side of the gate.

In another embodiment, a method of forming a device is disclosed. The method includes providing a substrate having a device region which comprises a source region, a gate and a drain region defined thereon. The method also includes forming a drift well in the substrate between the gate and drain region. The gate is implanted. The gate comprises one or more doped portions with different dopant concentrations. A source and a drain are formed in the source region and drain region. The drain is separated from the gate on a second side of the gate and the source is adjacent to a first side of the gate.

In yet another embodiment, a device is presented. The device includes a substrate having a device region which comprises a source region, a gate and a drain region defined thereon. The gate comprises one or more doped portions with different dopant concentrations. The device also includes a source and a drain in the source region and drain region. The drain is separated from the gate on a second side of the gate and the source is adjacent to a first side of the gate.

These and other objects, along with advantages and features of the present invention herein disclosed, will become apparent through reference to the following description and the accompanying drawings. Furthermore, it is to be understood that the features of the various embodiments described herein are not mutually exclusive and can exist in various combinations and permutations.

BRIEF DESCRIPTION OF THE DRAWINGS

In the drawings, like reference characters generally refer to the same parts throughout the different views. Also, the drawings are not necessarily to scale, emphasis instead generally being placed upon illustrating the principles of the invention. In the following description, various embodiments of the present invention are described with reference to the following drawings, in which:

FIGS. 1 a-c show embodiments of a device;

FIGS. 2 a-h show an embodiment of a process for forming a device; and

FIGS. 3 a-g show another embodiment of a process for forming a device.

DETAILED DESCRIPTION

Embodiments generally relate to semiconductor devices or integrated circuits (ICs). More particularly, some embodiments relate to high power devices. For example, high power devices include lateral double-diffused (LD) transistors, such as metal oxide transistors (MOS). The high power devices can be employed as switching voltage regulators for power management applications. The LD transistors can be easily integrated into devices or ICs. The devices or ICs can be incorporated into or used with, for example, consumer electronic products, and particularly portable consumer products, such as cell phones, laptop computers and personal digital assistants (PDAs).

FIGS. 1 a-c show cross-sectional views of a portion of embodiments of a device 100. The device, for example, is an IC. In one embodiment, the device is a laterally diffused metal oxide semiconductor (LDMOS). Other types of devices may also be useful. As shown, the device includes a substrate 105. The substrate, for example, is a silicon substrate. Other types of substrates, such as silicon germanium, germanium, gallium arsenide, or crystal-on-insulator (COI) such as silicon-on-insulator (SOI), are also useful. The substrate may be a doped substrate. For example, the substrate can be lightly doped with p-type dopants. Providing a substrate with other types of dopants or dopant concentrations, as well as an undoped substrate, may also be useful.

The device may include doped regions having different dopant concentrations. For example, the device may include heavily doped (x⁺), intermediately doped (x) and lightly doped (x⁻) regions, where x is the polarity type which can be p or n. A lightly doped region may have a dopant concentration of about 1E11-1E13/cm², and an intermediately doped region may have a dopant concentration of about 1E13-E14/cm², and a heavily doped region may have a dopant concentration of about 1E15-1E17/cm². Providing other dopant concentrations for the different types of doped regions may also be useful. P-type dopants may include boron (B), aluminum (Al), indium (In) or a combination thereof, while n-type dopants may include phosphorous (P), arsenic (As), antimony (Sb) or a combination thereof.

The substrate includes a device region. The device region, for example, is a high voltage (HV) device region for a high voltage device, such as a high voltage transistor. In one embodiment, the device region includes a LD transistor. Providing other types of devices in the device region may also be useful. The substrate may also include regions for other types of circuitry, depending on the type of device or IC. For example, the device may also include regions for intermediate voltage (IV) and low voltage (LV) voltage devices as well as an array region for memory devices.

Isolation regions may be provided for isolating or separating different regions of the substrate. In one embodiment, the device region is isolated from other regions by a device isolation region 180. For example, the device isolation region surrounds the device region. The isolation region, for example, is a shallow trench isolation (STI) region. Other types of isolation regions may also be employed. For example, the isolation region may be a deep trench isolation (DTI) region. The STI regions, for example, extend to a depth of about 2000-5000 Å. In the case of DTI regions, the depth may be about 1-10 μm. Providing isolation regions which extend to other depths may also be useful.

The transistor includes a gate 140 on the surface of the substrate. The width of the gate along a channel length direction of the transistor, for example, is about 0.5-10 μm. Providing a gate having other widths may also be useful. The gate may be a gate conductor which forms gates of multiple transistors. For example, the gate conductor may traverse a plurality of device regions separated by isolation regions. The pluralities of transistors have a common gate formed by the gate conductor. Other configurations of gate conductors may also be useful.

The gate, for example, includes a gate electrode 144 over a gate dielectric 142. The gate dielectric, for example, may be silicon oxide while the gate electrode may be polysilicon. The gate dielectric, for example, may be a high voltage gate dielectric having a thickness of about 30-1000 Å while the gate electrode may be about 500-5000 Å thick. Other types of gate dielectrics and gate electrodes as well as thicknesses may also be useful. For example, the gate dielectric may be a high k gate dielectric. Other configurations of gate layers of the gate may also be useful.

The transistor also includes first and second doped regions 132 and 134 disposed in the substrate on first and second sides of the gate. For example, the first doped region is disposed on the first side of the gate and the second doped region is disposed on the second side of the gate. The doped regions, in one embodiment, are heavily doped with first polarity type dopants for a first type transistor. For example, the doped regions are heavily doped n-type n⁺ regions for a n-type transistor. Providing heavily doped p-type (p⁺) regions may also be useful for a p-type transistor. The heavily doped regions, for example, have a dopant concentration of about 1E15-1E16/cm². Other dopant concentrations for the doped regions may also be useful. The depth of the doped regions may be about 0.1-0.4 μm. Providing doped regions having other depths may also be useful. Additionally, it is not necessary that the first and second doped regions have the same depth.

In one embodiment, the first doped region serves as a source region of the transistor. The source region is adjacent to the first side and underlaps the gate. The underlap portion should be sufficient for the source region to be in communication with the channel under the gate. The underlap portion may be, for example, about 0.1-0.5 μm. An underlap portion which underlaps the gate by other amounts may also be useful. In one embodiment, the underlap portion of the source region is a lightly doped source (LDS) region. Other configurations of the first doped region may also be useful.

Sidewalls of the gate may be provided with dielectric spacers 148. The dielectric spacers, for example, may be silicon oxide spacers. Other types of dielectric materials may also be useful, such as silicon nitride or a combination of dielectric materials or layers. For example, the spacers may be composite spacers. The spacers may include an offset spacer and main spacer. The offset spacers may facilitate forming the LDS region while the main spacers facilitate forming heavily doped source and drain regions. Other configurations of spacers may also be useful. For example, the spacer may be a single spacer. The LDS region is formed prior to forming the spacers while the spacers facilitate forming the heavily doped source and drain regions. In some cases, the transistor may also include halo regions. Halo regions are second polarity doped regions abutting the S/D regions proximate to the gate.

In some embodiments, a dielectric etch stop layer (not shown) is formed over the transistors. The etch stop layer, for example, is a silicon nitride etch stop layer. Other types of etch stop layers may also be useful. The etch stop layer should have a material which can be selectively removed from a dielectric layer thereover. The etch stop layer facilitates in forming contact plugs to contact regions of the transistor, such as the gate electrode and doped regions. In some embodiments, the etch stop layer may also serve as a stress layer for applying a stress on the channel of the transistor to improve performance.

In one embodiment, an internal isolation region 185 is provided within the device region. The internal isolation region may be an STI region. Other types of isolation regions may also be useful. Preferably, the internal isolation region is the same type of isolation region as the device isolation region. Providing an internal isolation region which is different from the device isolation region may also be useful. The internal isolation region, for example, is disposed in the device region along a channel width direction of the transistor between the gate and drain. The internal isolation, for example, extends from one side to the other side of the device region along the channel width direction. Other configurations of the device and internal isolation regions may also be useful. As shown, the internal isolation region underlaps the gate. For example, the internal isolation region extends under the second side of the gate by about 0.1-0.3 μm. Providing an internal isolation region which extends under the second side of the gate by other width may also be useful. Providing the internal isolation region which underlaps the gate protects the edge of the gate dielectric from high electric field during operation. The width of the internal isolation region, for example, may be about 0.2-5 μm. Other widths may also be useful, depending on the drain voltage. The width and depth of the internal isolation region may determine a drift length of the transistor. In other embodiments, no internal isolation region is provided, as shown in FIG. 1 c.

A drift well 150 is disposed in the substrate. The drift well is disposed in the device region. In one embodiment, the drift well connects the drain region to the channel of the transistor. The drift well, for example, is disposed below the drain region and extends under the gate. The gate overlaps the drift well, creating a gate overlap region O_(gate) in the drift well. In the case of where an internal isolation region is provided, the O_(gate) is between an edge of the drift well (e.g., inner edge of the drift well) under the gate and an edge of the internal isolation region (e.g., inner edge of the internal isolation region) under the gate. The O_(gate) region should be sufficiently wide to provide the desired on resistance and drive current. In one embodiment, O_(gate) is about 0.2-2 μm. Providing other values of O_(gate) may also be useful. The width, for example, may depend on design requirements.

In one embodiment, the depth or bottom of the drift well is below the device isolation and internal device isolation regions. For example, the drift well extends from a bottom of the device isolation region to under the gate. The depth of the drift well may be about 0.1-5 μm. Other depths may also be useful. The depth, for example, may depend on the design voltage of the device. The substrate under the gate between the source region and drift well forms a channel of the transistor. The distance from the drain and around the internal isolation region to the channel under the gate is the drift distance of the transistor.

The drift well includes first polarity type dopants. In one embodiment, the dopant concentration of the drift well is lower than the dopant concentration of the drain. In one embodiment, the drift well may be lightly (x⁻) or intermediately (x) doped with first polarity type dopants. For example, the dopant concentration of the drift well is about 1E12-1E14/cm². Other dopant concentrations may also be useful. For example, the dopant concentration may depend on the maximum or breakdown voltage requirement of the device.

A device well 170 may be disposed in the substrate. In one embodiment, the device well is disposed within the device isolation region. For example, the device well is disposed within the device isolation region, encompassing the source, drain, drift well and internal device isolation region. In one embodiment, the depth or bottom of the device well is below the source, drain and drift well. In one embodiment, the depth or bottom of the device well is below the device isolation region and internal device isolation region. Providing a device well at other depths may also be useful. For example, the device well may be at about the same depth as the drift well, as shown in FIG. 1 b. The device well may also be shallower than the drift well. The device well may be, for example, on both sides of the drift well. Other configurations of the device and drift well may also be useful. For example, the drift well may only be on one side of the drift well encompassing the source region and channel of the device.

The device well includes second polarity dopants for a first polarity type device. For example, the device well comprises p-type dopants for an n-type device or n-type dopants for a p-type device. The dopant concentration may depend on the voltage requirement of the device. The device well may be lightly (x⁻) or intermediately (x) doped with first polarity type dopants. Other dopant concentration for the device well, for example, dopant concentration greater than that of the lightly doped substrate, may also be useful.

In other embodiments, the device well may be provided by a doped substrate. For example, the substrate itself, if appropriately doped, may serve as a device well.

Salicide contacts 128 may be formed on the gate electrode of the gate and source and drain regions. The salicide contacts, for example, may be nickel-based contacts. Other types of metal salicide contacts may also be useful. For example, the salicide contact may be cobalt silicide (CoSi). The salicide contacts may be about 100-500 Å thick. Other thickness of salicide contacts may also be useful. The salicide contacts may be employed to reduce contact resistance and facilitate contact to the back-end-of-line metal interconnects.

In the case with no internal isolation regions, as shown in FIG. 1 c, a salicide block 199 may be provided to prevent salicidation of the substrate between the gate and drain region. For example, the salicide block prevents salicidation of the substrate in the drift region. This, for example, provides a high resistance drift region to sustain high voltage applied to the drain. As shown, the salicide block slightly overlaps the gate and drain. The overlap may be, for example, about 0.05-0.5 μm. This overlap may be due to alignment or processing margins to provide reliable process window. However, it is understood that the salicide block may also be aligned with the edge of the gate and drain region.

The salicide block, for example, is formed from a material on which silicidation does not occur. In one embodiment, the salicide block is formed of a dielectric material. The dielectric material, for example, may be oxide, nitride, oxynitride or a combination thereof. Other types of dielectric materials, such as those compatible for semiconductor processing, may also be useful. The salicide block may be formed with a plurality of layers to form, for example, a block stack or sandwich. Other configurations of salicide blocks may also be useful. The salicide block may be about 200-800 Å thick. Other thicknesses of salicide block may also be useful. Providing salicide blocks to prevent salicidation is described in co-pending U.S. patent application Ser. No. 13/189,573, which is herein incorporated by reference for all purposes. The salicide block may be subsequently removed or remain after formation of the salicide contacts.

In one embodiment, the gate is a split doped gate. The split doped gate includes a split doped gate electrode having different doped portions along the channel length direction of the gate. In one embodiment, the split doped gate electrode is a polysilicon split doped gate electrode. Other types of split doped gate electrode may also be useful. In one embodiment, the split doped gate electrode comprises more than one portion along the channel length direction of the gate. In one embodiment, the split doped gate electrode has an interface of first and second portions at about an inner edge of the drift region. In one embodiment, the first portion is at least over the channel of the transistor and the second portion may be over about the O_(gate) region.

In one embodiment, the first portion is a first doped region. The first portion is doped with first polarity type dopants. For example, the first portion has the same polarity type dopants as the source and drain of the transistor. In one embodiment, the first portion is heavily doped with first polarity type dopants. The first portion, for example, has about the same concentration as the source and drain regions. Heavily doping the first portion minimizes poly depletion effect over the channel. This improves gate control over the channel. In one embodiment, the first portion of the gate may overlap slightly over the O_(gate) region. This ensures that the gate electrode depletion effect over the channel is minimized.

In one embodiment, the second portion is a second doped region. In one embodiment, the second portion is doped with the same polarity type dopants as the first portion. In one embodiment, the second portion is less doped with respect to the first portion. Less doped includes any dopant concentration which is lower than the dopant concentration with which it is compared. For example, the second portion can include any dopant concentration which is lower than the first portion. For example, the second portion may be lightly doped. For example, the second portion may have the same concentration as the LDS region. In other embodiments, the second portion is undoped. Providing the second portion with second polarity type dopants may also be useful. For example, the second portion may be doped with dopants which are of a different polarity type than the source or drain region.

The second portion over the O_(gate) region, due to being lightly doped or undoped, has a greater gate electrode or poly depletion effect. This increases the effective gate oxide thickness over the O_(gate) region. A greater gate oxide thickness over the drift region reduces C_(gd), which improves device performance. The reduction in C_(gd) is achieved without increasing the size of O_(gate). This improves switching speed of the device without affecting drive current or Rds_(on).

In one embodiment, the second portion is slightly smaller than the O_(gate) region. This ensures that the gate electrode depletion region does not occur over the channel region. In one embodiment, the inner edge of the drift well underlaps the first portion of the split gate electrode to minimize poly depletion in the first portion. In one embodiment, the channel length from the source to inner edge of the drift well is about the same as the width of the O_(gate) region.

In one embodiment, the split doped gate has a third portion (not shown) which may be over about the STI region 185. The second portion which is between the first and third portions is disposed over the O_(gate) region. The third portion may be doped with dopants of the same polarity type and concentration as the first portion. The third portion may also include dopants of the same polarity type and concentration as the second portion. The third portion including dopants of other concentrations may also be useful. The split doped gate with other configurations may also be useful.

FIGS. 2 a-h show cross-sectional views of an embodiment of a process for forming a device 200. Referring to FIG. 2 a, a substrate 105 is provided. The substrate, in one embodiment, is a silicon substrate. The substrate may be a doped substrate, such as a p⁻ substrate. Other types of substrates, such as a germanium-based, gallium arsenide, COI such as SOI, or sapphire, may also be useful. The substrates may be doped with other types of dopants or dopant concentrations.

In some embodiment, the substrate may include a base substrate with a surface substrate disposed thereon. The base and surface substrates may be, for example, silicon. In one embodiment, the surface substrate is an epi surface substrate. Other types of semiconductor materials for the base and surface substrates may also be useful. It is understood that the base and surface substrates need not be the same material.

In one embodiment, the base substrate is a p⁺ substrate and the surface substrate is a p⁻ substrate. Providing substrates with other dopant concentrations or different types of dopants, including no dopants, may also be useful. In some embodiments, a buried well of the opposite polarity as the surface substrate may be provided. The buried well, for example, may be a heavily doped well of the opposite polarity as the surface substrate. In one embodiment, a n⁺ buried well is to separate the p− surface epi substrate from a p− base substrate. The n⁺ buried well may be a part of the base substrate. Other configurations of base substrate, surface substrate and buried well may also be useful.

As shown, a device region is defined on the substrate. Although one device region is shown, it is however understood that the substrate may include various types of regions (not shown). For example, the substrate may include other device regions for other types of devices. The IC may include logic regions in which logic devices are formed. Depending on the type of IC formed, the logic regions, for example, may include regions for different voltage devices. For example, the logic regions may include regions for high voltage (HV) devices, medium or intermediate voltage (IV) devices and low voltage (LV) devices. Other configurations of logic regions may also be useful. Additionally, other types of device regions may also be provided.

In one embodiment, the device region is a HV region. The device region, for example, serves as a device region for a LD transistor. Providing a device region for other types of devices may also be useful. The device region is separated from other regions by a device isolation region 180. The device isolation region surrounds the device region. In one embodiment, the device region also includes an internal device isolation region 185 to separate the device region into first and second device sub-regions. For example, the internal device isolation region separates the device region into first and second sub-regions on the surface of the substrate.

In one embodiment, an internal isolation region 185 is provided within the device region. The internal isolation region, for example, is disposed in the device region along a channel width direction of the transistor between the gate and drain. The internal isolation, for example, extends from one side to the other side of the device region along the channel length direction.

The isolation regions are, for example, STIs. Various processes can be employed to form the STI regions. For example, the substrate can be etched using etch and mask techniques to form trenches which are then filled with dielectric materials such as silicon oxide. Chemical mechanical polishing (CMP) can be performed to remove excess oxide and provide a planar substrate top surface. Other processes or materials can also be used to form the STIs. The depth of the STIs may be, for example, about 2000-6000 Å. Other depths for the STIs may also be useful. In other embodiments, the isolation may be other types of isolation regions. Also, the device and internal isolation regions may be different types of isolation regions.

As shown in FIG. 2 b, a doped well 150 is formed in the device region. The doped well serves as a drift well for the device. In one embodiment, the drift well is disposed in a portion of the device region. The drift well, for example, encompasses the internal isolation region and a portion of the device isolation region on a second side of the device region. The depth of the drift well, for example, may be about 0.1-5 μm. Providing a drift well of other depths may also be useful. The depth of the drift well, for example, may depend on the design requirements. The drift well includes first polarity type dopants for a first polarity type device. For example, a n-type drift well is provided for a n-type device. The n-type drift well, for example, may include phosphorus dopants. Forming a p-type drift well for a p-type device may also be useful. In one embodiment, the drift well may be lightly or intermediately doped with first polarity type dopants. Other dopant concentration for the first drift well may also be useful.

In some embodiment, a device doped well 170 is formed in the device region, as shown in FIG. 2 c. The device well serves as a body well for the transistor. The device well includes second polarity type dopants. In one embodiment, the device well is a lightly doped device well. For example, the dopant concentration of the device well is about 1E13-1E14/cm². The device well, in one embodiment, encompasses the drift well and internal isolation region. In one embodiment, the device well encompasses a portion of the device isolation region, internal isolation region and drift well. The depth of the device well, for example, is about 0.5-6 μm. Other depths for the device well may also be useful. In other embodiments, the device well and drift well may have about the same depth. For example, the device well may be on both sides of the drift well. Other configurations of the device and drift well may also be useful. The drift well, for example, may only be on one side of the drift well encompassing the source region and channel of the device.

To form a doped well, an implant mask which exposes the device region is used. The implant mask, for example, comprises photoresist patterned by a lithographic mask. Dopants are implanted into the substrate using the implant mask. The dopants are implanted with the appropriate dose and power. Separate implant processes with respective implant masks are used to form doped wells of different polarity types. For example, separate processes are used to form the drift and device wells. In one embodiment, the device well is formed prior to forming the drift well. In some embodiments, a doped well may be formed by, for example, performing multiple implants at different energies. For example, the device well may be formed using multiple implant processes. Other configurations of implant processes may also be employed to form the wells.

The implant processes used to form the device wells may be compatible or the same as processes used to form other similar types of wells in the device. For example, the processes may be compatible with those used in current CMOS processes for forming similar types of wells. For example, the device well may be formed at the same time as the low voltage device or intermediate voltage device well. This allows the same lithographic mask of the current CMOS implant mask to be used to pattern the implant mask for the device well. For example, the current CMOS implant mask may be customized to include the device well opening. In other embodiments, a separate device well mask may be used to specifically tailor for the doping of the device well. In such cases, the same mask can also be used to form the second device well.

An anneal is performed. In one embodiment, the anneal is performed after the drift and device wells are formed. The anneal activates the dopants. In other embodiments, separate anneals may be performed for the drift and device wells. For example, an anneal may be performed after forming a doped well.

As shown in FIG. 2 d, gate layers of a gate are formed on the substrate. In one embodiment, the gate layers include a gate dielectric layer 242 on the substrate and a gate electrode layer 244 thereon. The gate dielectric layer, for example, is silicon oxide. The thickness of the gate dielectric layer may be about 30-1000 Å. Other thicknesses may also be useful. For example, the gate dielectric layer is a high voltage gate dielectric layer. The gate dielectric layer may be formed by thermal oxidation. For example, the dielectric layer is formed by wet oxidation followed by annealing the substrate in an oxidizing ambient. The temperature of the wet oxidation can be, for example, about 600-1000° C. The annealing can be, for example, performed at a temperature of about 1000° C. Forming other types of gate dielectric layers or using other processes may also be useful.

In one embodiment, the gate electrode layer is a silicon layer. The silicon layer, for example, may be a polysilicon layer. The thickness of the gate electrode layer may be about 500-5000 Å. Other thickness may also be useful. The gate electrode layer may be formed by, for example, CVD. Other techniques for forming the gate electrode layer may also be useful. The gate electrode layer can be formed as an amorphous or non-amorphous layer. In the case of an amorphous layer, an anneal may be performed to form a polycrystalline silicon layer.

Other types of gate dielectric and gate electrode materials or thicknesses may also be useful. For example, the gate dielectric material may be a high k dielectric material while the gate electrode may be a metal gate electrode material. Other configuration of gate layers may also be useful. For example, the gate dielectric and/or gate electrode layers may have multiple layers. The layers can be formed by various techniques, such as thermal oxidation, CVD and sputtering.

Referring to FIG. 2 e, a mask layer 249 is formed on the substrate. The mask layer, for example, is formed over the gate electrode layer. In one embodiment, the mask layer is a soft mask layer, such as a photoresist layer. An exposure source may selectively expose the photoresist layer through a reticle containing the desired pattern. After selectively exposing the photoresist layer, it is developed to form openings corresponding to locations when the gate layers are to be removed. To improve lithographic resolution, an anti-reflective coating (ARC) may be used below the photoresist layer.

In other embodiments, the mask layer may be a hard mask layer. The hard mask layer, for example, may comprise TEOS or silicon nitride. Other types of hard mask materials may also be used. The hard mask layer may be patterned using a soft mask, such as a photoresist.

The patterned mask layer serves as an etch mask for a subsequent etch process, as shown in FIG. 2 f. For example, the etch transfers the pattern of the mask to the gate layers. The etch removes the gate layers unprotected by the mask, exposing the substrate. The etch, for example, may be an anisotropic etch, such as reactive ion etch (RIE). Other types of etch processes may also be useful. In one embodiment, an RIE is employed to pattern the gate layers to form a gate 140. The gate, in one embodiment, overlaps the drift well, forming an overlap O_(gate) region. The gate, for example, may be a gate conductor which serves as a common gate for multiple transistors. Other configurations of the gate may also be useful.

In one embodiment, lightly doped region 232 is formed on the substrate in the source region of the device. The lightly doped region has first polarity type dopants. To form the lightly doped region, first polarity type dopants are implanted into the substrate. The implant, for example, may be self-aligned with respect to the device region. For example, the implant may dope the substrate unprotected by the gate and isolation region. The depth of the lightly doped regions, for example, is about 0.1-0.5 μm. The implant dose may be about 1E13-1E14/cm² and the implant energy may be about 1-200 KeV. Other implant parameters may also be useful. In one embodiment, forming the lightly doped region in the source region also forms a lightly doped region 234 in the drain region. The implant that forms the lightly doped regions may be self-aligned with respect to the device region. For example, an implant mask which exposes the device region may be provided. The gate and insulation regions provide self-alignment in the device region. The implant mask may be a photoresist layer. Other types of implant masks may also be useful.

In one embodiment, the implant to form the lighted doped region or lightly doped regions also dopes the gate electrode. In one embodiment, the implant forms lightly doped region or regions and lightly doped gate electrode. For example, the self-aligned implant with respect to the device region forms lightly doped regions and lightly doped gate electrode. In alternative embodiments, the implant mask may protect a second region 146 of the gate. This allows a first region 141 of the gate to be lightly doped by the implant while leaving the second region undoped. The interface of the first and second regions, for example, is at about an inner edge of the drift well. Providing the interface at other parts of the gate electrode may also be useful. For example, the mask may protect the second region and extend to cover a part of the internal isolation region. In an alternatively embodiment, the gate electrode may be protected by the implant mask to prevent doping of the gate. Other configurations of doping the gate electrode may also be useful. For example, multiple implant processes may be performed to provide different doping for gate electrodes and lightly doped regions. In such cases, different implant masks may be employed for different implant processes.

Sidewall spacers 148 may be formed on the sidewalls of the gates. The implant masks employed to prevent doping of the second portion or the gate electrode may be removed prior to the formation of the sidewall spacers. To form the sidewall spacers, a dielectric layer is deposited on the substrate. The dielectric layer, for example, may be silicon oxide. Other types of dielectric material, such as silicon nitride, may also be used. The dielectric layer may be formed by CVD. The dielectric layer may also be formed using other techniques. The thickness of the dielectric layer may be, for example, 300-1000 Å. Other thickness for the dielectric layer may also be useful. The thickness, for example, may depend on the desired width of the spacers. An anisotropic etch, such as RIE, may be performed to remove horizontal portions of the dielectric layer, leaving spacers on the sidewalls of the gate. In some applications, the spacer may be formed from multiple dielectric layers.

Referring to FIG. 2 g, heavily doped regions 132 and 134 are formed in the source and drain regions on the substrate. The heavily doped regions have first polarity type dopants. Forming the heavily doped regions includes implanting first polarity type dopants into the substrate. The implant, like the one that forms the lightly doped regions, is self-aligned with respect to the device region. For example, the dopants may be doped into the substrate unprotected by the gate and isolation regions. In this case, the sidewall spacers cause the heavily doped source region to be offset, creating a source which includes a lightly doped source portion and a heavily doped deeper portion. The depth of the heavily doped regions, for example, is about 0.1-0.5 μm. The implant dose may be about 1E15-1E16/cm² and the implant energy may be about 1-100 KeV. Other implant parameters may also be useful.

In one embodiment, the implant to form heavily doped regions also heavily dopes a heavily doped first portion of the gate electrode. As for the second portion, it may be lightly doped or undoped. For example, if the gate electrode is unprotected during formation of the lightly doped regions and the second portion is protected by an implant mask during formation of the heavily doped regions, the second region would be lightly doped. On the other hand, if the gate electrode or second region of the gate electrode is protected during formation of the lightly doped region and during formation of the heavily doped regions, then the second region is undoped.

In one embodiment, salicide contacts 128 are formed on contact regions of the transistor as shown in FIG. 2 h. For example, the salicide contacts are formed on the gate and source and drain of the transistor. The salicide contacts are to facilitate low resistance contacts between the active substrate and the BEOL metal lines. In one embodiment, the thickness of the salicide contacts is about 200 Å. Providing other thicknesses may also be useful.

To form the salicide contacts, a metal layer is deposited on the surface of the substrate. The metal layer, for example, may be nickel or an alloy thereof. Other types of metallic layers, such as cobalt, or alloys thereof, including nickel, may also be used. The metal layer can be formed by Physical Vapor Deposition (PVD). Other types of metal elements and/or be formed by other types of processes can also be useful.

A first anneal may be performed. The first anneal diffuses the metal dopants into the active substrate, forming a silicided layer. The first anneal, for example, is performed at a temperature of about 300-600° C. for about 10-60 seconds. Excess metal not used in the silicidation of the active surface is removed by, for example, a wet removal process. For example, unreacted metal material is removed selective to the salicide contacts. A second anneal may be performed to enhance the material properties of the silicided layer, for example, lower resistivity. The first and second annealing processes may be a rapid thermal anneal (RTA). Other annealing parameters or techniques may also be useful to form the salicide contacts.

The process continues to form the device. The processing may include forming a PMD layer and contacts to the terminals of the cell as well as one or more interconnect levels, final passivation, dicing, assembly and packaging. Other processes may also be included. For example, other components, such as low voltage, medium voltage, and high voltage I/O devices can be formed prior to forming the interconnections.

FIGS. 3 a-g show cross-sectional views of an embodiment of a process for forming another device 300. The process may contain similar elements or process steps as the process described in FIGS. 2 a-h. As such, the common elements or process steps may not be described or described in detail.

In one embodiment, a device isolation region 180 is formed on the substrate, as shown in FIG. 3 a. The isolation regions are, for example, STIs. Various processes can be employed to form the STI regions. For example, the substrate can be etched using etch and mask techniques to form trenches which are then filled with dielectric materials such as silicon oxide. Chemical mechanical polishing (CMP) can be performed to remove excess oxide and provide a planar substrate top surface. Other processes or materials can also be used to form the STIs. The depth of the STIs may be, for example, about 2000-6000 Å. Other depths for the STIs may also be useful. In other embodiments, the isolation may be other types of isolation regions. Also, the device and internal isolation regions may be different types of isolation regions.

As shown in FIG. 3 b, a doped well 150 is formed in the device region. The doped well serves as a drift well for the device. In one embodiment, the drift well is disposed in a portion of the device region. The drift well, for example, encompasses a portion of the device isolation region on a second side of the device region. The depth of the drift well, for example, may be about 0.1-5 μm. Providing a drift well of other depths may also be useful. The depth of the drift well, for example, may depend on the device operation voltage. The drift well includes first polarity type dopants for a first polarity type device. For example, a n-type drift well is provided for a n-type device. The n-type drift well, for example, may include phosphorus dopants. Forming a p-type drift well for a p-type device may also be useful. In one embodiment, the drift well may be lightly or intermediately doped with first polarity type dopants. Other dopant concentration for the first drift well may also be useful.

In some embodiment, a device doped well is formed in the device region, as shown in FIG. 3 c. The device well serves as a body well for the transistor. The device well includes second polarity type dopants. In one embodiment, the device well is a lightly doped device well. For example, the dopant concentration of the device well is about 1E13-1E14/cm². The device well, in one embodiment, encompasses the drift well. In one embodiment, the device well encompasses a portion of the device isolation region and drift well. The depth of the device well, for example, is about 0.5-6 μm. Other depths for the device well may also be useful. In other embodiments, the device well and drift well may have about the same depth. For example, the device well may be on both sides of the drift well. Other configurations of the device and drift well may also be useful. The drift well, for example, may only be on one side of the drift well encompassing the source region and channel of the device.

To form a doped well, an implant mask which exposes the device region is used. The implant mask, for example, comprises photoresist patterned by a lithographic mask. Dopants are implanted into the substrate using the implant mask. The dopants are implanted with the appropriate dose and power. Separate implant processes with respective implant masks are used to form doped wells of different polarity types. For example, separate processes are used to form the drift and device wells. In one embodiment, the device well is formed prior to forming the drift well. In some embodiments, a doped well may be formed by, for example, performing multiple implants at different energies. For example, the device well may be formed using multiple implant processes. Other configurations of implant processes may also be employed to form the wells.

The implant processes used to form the device wells may be compatible or the same as processes used to form other similar types of wells in the device. For example, the processes may be compatible with those used in current CMOS processes for forming similar types of wells. For example, the device well may be formed at the same time as the low voltage device or intermediate voltage device well. This allows the same lithographic mask of the current CMOS implant mask to be used to pattern the implant mask for the device well. For example, the current CMOS implant mask may be customized to include the device well opening. In other embodiments, a separate device well mask may be used to specifically tailor for the doping of the device well. In such cases, the same mask can also be used to form the second device well.

An anneal is performed. In one embodiment, the anneal is performed after the drift and device wells are formed. The anneal activates the dopants. In other embodiments, separate anneals may be performed for the drift and device wells. For example, an anneal may be performed after forming a doped well.

Referring to FIG. 3 d, the substrate is processed to form a gate 140, similar to that described in FIGS. 2 d-f. For example, a gate dielectric 142 and gate electrode layer 144 are formed on the substrate and patterned to form the gate. The gate, in one embodiment, overlaps the drift well, forming an overlap O_(gate) region. The gate, for example, may be a gate conductor which serves as a common gate for multiple transistors. Other configurations of the gate may also be useful.

In FIG. 3 e, the process continues to form a lightly doped region 232 is formed on the substrate in the source region of the device. The lightly doped region has first polarity type dopants. To form the lightly doped region, first polarity type dopants are implanted into the substrate. An implant mask may be formed over the drift well to prevent it from being doped. The implant mask may be a photoresist layer. Other types of implant masks may also be useful. The implant, for example, may be self-aligned with respect to the device region. For example, the implant may dope the substrate unprotected by the gate, isolation region and the implant mask. The depth of the lightly doped regions, for example, may be about 0.1-0.4 μm. The implant dose may be about 5E12-5E13/cm² and the implant energy may be about 10-100 KeV. Other implant parameters may also be useful.

In one embodiment, the implant to form the lightly doped region also dopes the gate electrode. In one embodiment, the implant forms the lightly doped region and the lightly doped gate electrode. For example, a non self-aligned implant forms the lightly doped region and the lightly doped gate electrode. In alternative embodiments, the implant mask may protect a second region 146 of the gate. This allows a first region 141 of the gate to be lightly doped by the implant while leaving the second region undoped. The interface of the first and second regions, for example, is at about an inner edge of the drift well. Providing the interface at other parts of the gate electrode may also be useful. The internal isolation region may improve process window. For example, the mask may protect the second region and extend to cover a part of the internal isolation region. In an alternatively embodiment, the gate electrode may be protected by the implant mask to prevent doping of the gate. Other configurations of doping the gate electrode may also be useful. For example, multiple implant processes may be performed to provide different doping for gate electrodes and lightly doped regions. In such cases, different implant masks may be employed for different implant processes.

Sidewall spacers 148 may be formed on the sidewalls of the gates. The implant masks employed to prevent doping of the second portion or the gate electrode may be removed prior to the formation of the sidewall spacers. To form the sidewall spacers, a dielectric layer is deposited on the substrate. The dielectric layer, for example, may be silicon oxide. Other types of dielectric material, such as silicon nitride, may also be used. The dielectric layer may be formed by CVD. The dielectric layer may also be formed using other techniques. The thickness of the dielectric layer may be, for example, 300-1000 Å. Other thickness for the dielectric layer may also be useful. The thickness, for example, may depend on the desired width of the spacers. An anisotropic etch, such as RIE, may be performed to remove horizontal portions of the dielectric layer, leaving spacers on the sidewalls of the gate. In some applications, the spacer may be formed from multiple dielectric layers.

Referring to FIG. 3 f, heavily doped regions 132 and 134 are formed in the source and drain regions on the substrate. The heavily doped regions have first polarity type dopants. Forming the heavily doped regions includes implanting first polarity type dopants into the substrate. The implant, like the one that forms the lightly doped regions, is self-aligned with respect to the device region. For example, the dopants may be doped into the substrate unprotected by the gate and isolation regions. In this case, the sidewall spacers cause the heavily doped source region to be offset, creating a source which includes a lightly doped source portion and a heavily doped deeper portion. The depth of the lightly doped regions, for example, may be about 0.1-0.4 μm. The implant dose may be about 5E12-5E13/cm² and the implant energy may be 10-100 KeV. Other implant parameters may also be useful.

In one embodiment, the implant to form heavily doped regions also heavily dopes a heavily doped first portion of the gate electrode. As for the second portion, it may be lightly doped or undoped. For example, if the gate electrode is unprotected during formation of the lightly doped regions and the second portion is protected by an implant mask during formation of the heavily doped regions, the second region would be lightly doped. On the other hand, if the gate electrode or second region of the gate electrode is protected during formation of the lightly doped region and during formation of the heavily doped regions, then the second region is undoped.

In one embodiment, a salicide block layer is formed on the substrate. The salicide block layer prevents formation of salicide contacts on the substrate. In one embodiment, the salicide block layer is a dielectric layer. For example, the salicide block layer may be oxide, nitride, oxynitride or a combination thereof. Other types of dielectric materials or block materials, such as those compatible for semiconductor processing, may also be useful. In some embodiment, the salicide block layer may be a composite layer having a plurality of layers which form, for example, a block stack or sandwich. Other configurations of salicide block layers may also be useful. The salicide block layer may be about 200-800 Å thick. Other thickness of salicide block may also be useful. Various techniques may be used to form the salicide block layer. For example, the salicide block layer may be formed by CVD.

The salicide block layer is patterned to form a salicide block 199. The salicide block may be patterned using mask and etch techniques. For example, a photoresist layer is formed over the dielectric layer and patterned using a lithographic mask, exposing portions of the dielectric layer to be removed. An anisotropic etch, such as RIE, is performed to remove exposed portions of the dielectric layer. The sidewall spacers remain on the sidewalls of the gates. To improve lithographic resolution, an anti-reflective coating (ARC) can be provided beneath the photoresist. Other techniques for patterning the dielectric layer may also be useful.

The salicide block is disposed on the substrate over the drift region. The salicide block prevents formation of a silicide contact over the drift region. As shown, the silicide block covers the gate sidewall on the drain side and drift region. In one embodiment, the salicide block slightly overlaps the gate and/or drain. The overlap may be, for example, about 0.05-0.5 μm. This overlap may be due to alignment or processing margins to provide reliable process window. However, it is understood that the salicide block may also be aligned with the edge of the gate and drain region.

In one embodiment, salicide contacts 128 are formed on contact regions of the transistor as shown in FIG. 3 g. For example, the salicide contacts are formed on the gate and source and drain of the transistor. The salicide contacts are to facilitate low resistance contacts between the active substrate and the BEOL metal lines. In one embodiment, the thickness of the salicide contacts is about 200 Å. Providing other thicknesses may also be useful.

To form the salicide contacts, a metal layer is deposited on the surface of the substrate. The metal layer, for example, may be nickel or an alloy thereof. Other types of metallic layers, such as cobalt, or alloys thereof, including nickel, may also be used. The metal layer can be formed by Physical Vapor Deposition (PVD). Other types of metal elements and/or formed by other types of processes can also be useful.

A first anneal may be performed. The first anneal diffuses the metal dopants into the active substrate, forming a silicided layer. The first anneal, for example, is performed at a temperature of about 300-600° C. for about 10-60 seconds. Excess metal not used in the silicidation of the active surface is removed by, for example, a wet removal process. For example, unreacted metal material is removed selective to the salicide contacts. A second anneal may be performed to enhance the material properties of the silicided layer, for example, lower resistivity. The first and second annealing processes may be a rapid thermal anneal (RTA). Other annealing parameters or techniques may also be useful to form the salicide contacts.

In some embodiments, the salicide block spacer is removed in subsequent processes, for example, a wet removal process. Other removal processes, for example RIE, may also be useful.

The process continues to form the device. The processing may include forming a PMD layer and contacts to the terminals of the cell as well as one or more interconnect levels, final passivation, dicing, assembly and packaging. Other processes may also be included. For example, other components, such as low voltage, medium voltage, and high voltage I/O devices can be formed prior to forming the interconnections.

The various embodiments described herein may include field structures to increase gate dielectric breakdown voltage. For example, a field structure may be provided to surround the drain of a transistor. The field structure may be coupled to an opposite potential than the drain, such as the source, during operation. Such field structures are described, for example, in co-pending application Ser. No. 13/276,301 entitled “High Voltage Device”, which is herein incorporated by reference for all purposes.

The invention may be embodied in other specific forms without departing from the spirit or essential characteristics thereof. The foregoing embodiments, therefore, are to be considered in all respects illustrative rather than limiting the invention described herein. Scope of the invention is thus indicated by the appended claims, rather than by the foregoing description, and all changes that come within the meaning and range of equivalency of the claims are intended to be embraced therein. 

The invention claimed is:
 1. A device comprising: a substrate having a device region, wherein the device region comprises a source region, a gate and a drain region defined thereon; a drift well disposed in the substrate between the gate and drain region, wherein the drift well encompasses the drain region and underlaps a portion of the gate and creates a gate overlap region O_(gate) in the drift well, wherein the gate comprises one or more doped portions with different dopant concentrations, and the gate comprises a first doped portion and a second doped portion, the interface of the first and second doped portions is at about an inner edge of the drift well; and a source and a drain in the source region and drain region, wherein the drain is separated from the gate on a second side of the gate and the source is adjacent to a first side of the gate.
 2. The device of claim 1 comprises an internal device isolation region along a channel width direction in the substrate between the gate and drain.
 3. The device of claim 2 wherein: the drift well encompasses the internal device isolation region; and the drift well underlaps the portion of the gate and creates the gate overlap region O_(gate) between the inner edge of the drift well under the gate and an edge of the internal device isolation region under the gate.
 4. The device of claim 2 comprises a device well in the substrate, wherein the device well is at about the same depth as the drift well.
 5. The device of claim 2 comprises an isolation region, wherein the isolation region isolates the device region from other regions of the device.
 6. The device of claim 5 comprises a device well in the substrate, wherein a depth of the device well is below the isolation region.
 7. The method of claim 6 wherein the device well encompasses the source, drain, drift well and internal device isolation region.
 8. The device of claim 2 wherein: the first portion is at least over about a channel of the device between the source and the O_(gate) region; the first portion comprises a first dopant concentration C1; and the second portion comprises a second dopant concentration C2, wherein C2 is lower than C1.
 9. The device of claim 1 wherein: the first portion is at least over about a channel of the device between the source and the O_(gate) region; the first portion comprises a first dopant concentration C1; and the second portion comprises a second dopant concentration C2, wherein C2 is lower than C1.
 10. The device of claim 1 comprises a salicide block on the substrate over the drift well.
 11. A device comprising: a substrate having a device region, wherein the device region comprises a source region, a gate and a drain region defined thereon; and a drift well which comprises first polarity type dopants disposed in the substrate between the gate and drain region, wherein the drift well encompasses the drain region and underlaps a portion of the gate and creates a gate overlap region O_(gate) in the drift well, wherein the gate comprises one or more doped portions with different dopant concentrations, and the gate comprises a first doped portion and a second doped portion, the interface of the first and second doped portions is at about an inner edge of the drift well; and a source and a drain in the source region and drain region, wherein the drain is separated from the gate on a second side of the gate and the source is adjacent to a first side of the gate.
 12. The device of claim 11 wherein: the first portion is at least over about a channel of the device between the source and the O_(gate) region; the first portion comprises a first dopant concentration C1; and the second portion comprises a second dopant concentration C2, wherein C2 is lower than C1.
 13. A device comprising: a substrate having a device region, wherein the device region comprises a source, a gate and a drain defined thereon; and a drift well disposed in the substrate between the gate and drain, wherein the drift well encompasses the drain and underlaps a portion of the gate and creates a gate overlap region O_(gate) in the drift well, the gate comprises at least first and second portions with different dopant concentrations and an interface of the first and second portions of the gate is at about an inner edge of the drift well, and the drain is separated from the gate on a second side of the gate and the source is adjacent to a first side of the gate.
 14. The device of claim of claim 13 wherein the first portion is a heavily doped portion and the second portion is a lightly doped portion relative to the first portion.
 15. The device of claim 14 wherein the first and second portions of the gate comprise first polarity type dopants.
 16. The device of claim 14 comprises an internal device isolation region along a channel width direction in the substrate between the gate and drain.
 17. The device of claim 14 comprises a salicide block on the substrate over the drift well.
 18. The device of claim 13 wherein the first portion is a heavily doped region which comprises first polarity type dopants and the second portion is undoped.
 19. The device of claim 18 comprises an internal device isolation region along a channel width direction in the substrate between the gate and drain.
 20. The device of claim 18 comprises a salicide block on the substrate over the drift well. 